Unit 4a Vehicle Body Engg Cars

Automotive Aerodynamics & Body Engineering
Vehicle Body Engineering

Car Body Construction
R P Kakde
Govt College Of Engineering & Research Awasari
AABE by R P Kakde GCOEARA Awasari Khurd

Unit II Car Body Construction
After studying this chapter, we should be able to:

- Explain the current design of motor vehicles
Summarize the various types of frames commonly used on modern cars, trucks,
vans, and SUVs
Compare and contrast modern

GCOEARA body-over-frame
Awasari Khurd and unibody construction
technology
Locate the major parts of a perimeter frame ‘
Locate the major parts of a unibody frame ‘i) Compare a conventional full frame
with modern hydroformed frames Identify the major structural components,
sections, and assemblies of a motor vehicle
Explain how simulated and actual crash tests are used to evaluate the structural
integrity of a motor vehicle
Describe the lay person’s names for body shapes used on passenger vehicles
Answer ASE-style review questions relating to vehicle construction
AABE by R P Kakde GCOEARA Avasari Khurd

Unit II Car Body Construction
Identification & Functions of Body Pressings
• In a separate body and chassis construction :

• - Chassis resists bending & twisting loads
• - Body provides only functional needs
• Separate body & chassis type of construction is being
superseded by the integral or mono-construction system
• In integral construction the frame members become an
integral part of the body

Identification
Unit II & Functions ofCar
Body Pressings
Body Construction
• Car Body Assemblies

Unit IV Car Body Construction

• Car Underbody Assemblies

• Box sectioning of the body sills, door pillars and roof

reinforcements form a framed structure in which stresses
are distributed to all parts of the body
• In reinforced body shell buckling is prevented by use of
curved plates with multiple radii ( or crown ). A flat plate
offer little resistance to buckling.
• For stress carrying parts of body shell greater rigidity can
be achieved by using ‘ top of hat ‘ section or channel &
angles built into the assembly
• This is also convenient for construction of streamlined
shapes for minimum aerodynamic resistance's

• Mass production of car bodies in steel consists of manufacturing of sub-

assemblies like floor-pan, two sides, roof cross-member, etc. assembled
together and spot-welded to form a complete body shell
• For construction of a typical Car Body Shell various sub-assemblies generally
required are described in order to understand a sequence of its construction .

Sub- Assemblies & Construction of Body Shell
• Underbody assembly
• Body side assembly
• Shroud and dash panel assembly
• Roof & back window aperture panels
• The Center pillar ( B- C post )
• Rear Bulk-head and parcel shelf
• Front end work
• Front wings
• Door panel assembly



• Bonnet panel assembly
• Boot lid assembly
• Under body assembly
• - This positions the engine, transmission, wheel-
arches, seats, etc.
• - Body sills provide longitudinal edge reinforcements
• - The floor pan strengthened by; box members at right
angles to the transmission tunnel; all cross members

• Under body assembly

• at the rear,front of the front seats, front of the rear seats, etc. joined together provide lateral reinforcements
• - The transmission tunnel, which acts like an inverted channel section provide central strength built into the
floor
• - The remaining area of flat metal is ribbed or dished below the seats and in the foot wells to add stiffness to
the sub-assembly

• Body side assembly

• - The side frames reinforcing the floor pan,
body sills also transmit loads between them
Sub- • - The center pillars are welded in between the
body sill and the roof / cant rails.
Assemblies • - These are usually assembled as a box section
& using a ‘top-hat’ section and flat plate, with the
Construction flanges forming attachments for the door,
weather seals, etc.
of Body Shell • - The front hinge pillars extend forward to join
with the dash panel, front bulkhead cross
member. This provides strength by ‘boxing’ the
front end.



• Shroud & Dash panel assembly
• - These assemblies are complex structures connecting the
two body sides across the car
• - The complete assembly is also called the firewall because it
is the partition between the passenger and engine
compartment, and carries part of the forces set up by the
front suspension, weight of the power unit.
• - The heating / cooling systems & its distribution chamber,
instrument panel & its necessary controls, wiring, tubing,
etc., the steering column are all attached to the front bulk
head of the body and is


• usually formed by assembling together several smaller panels ( dash & shroud ) which are
joined by welds to form an integral unit.
• - The instrument panel connected to the cowl panel provides mountings for instruments.
• - In some cases the wind screen opening is connected to the cowl panel. In this case the
windscreen pillars, the narrow sloping construction at either side of the windscreen opening
are part of the cowl. Upper edge of the cowl panel forms the front edge of the roof panel
• - On many passenger cars the front door hinge pillar is also an integral part of the cowl
• - Roof panel is one of the largest of all major body panels and it is one of the simplest in
construction.
• - Usually it is all-steel, one piece construction.
• - On some cars it ends at the windscreen on front side & rear window on the rear side.
It may extend down
•



• wards around windscreen on front side and on rear side the rear window opening is
in the lower rear roof and forming the top panel around the rear boot opening
• - The roof and its reinforcing members form lid of the box structure.
• - The stiffness is built by the curvature given to it, the reinforcement consisting of
small metal strips placed crosswise to the roof at intervals along the inside surface.
These also provide tacking strips for securing
• the heal lining & inside trims in place . In some cases the roof panel is also ribbed or
dished longitudinally.
• The Center Pillar ( B - C post )
• - It acts as central roof and side support between the front and rear of the car body
side structure.
• - Its construction must be exceptionally strong as it is the shut ( lock ) pillar and the
hinge pillar for the doors.
• - The center pillar is irregular in shape since it must conform to outside contours of
the door as well as




• The Center Pillar ( B - C post )
• accommodate door lock, striker plate, hinges,etc.
depending on the body style.


• Rear Bulk - Head and Parcel Shelf
• - This provides transverse stiffness and is welded between the body side frames and rear seat frame. In
construction they are often pierced and flanged to increase rigidity.
• - The rear panel is curved to form part of the external shape of the body with its upper edge providing support
to the boot lid seal.

• Front End Work
• -The front end carries the engine and front suspension, steering gear and radiator.
• - The suspension system may affect detail design of the panels but the loads must be transmitted to the
wings and/or wheel arches and on into the body panels
• - The front cross- member assembly braces the front of the car and carries the radiator, headlamps, etc.
The side assemblies and front wheelhouse panel assembly form a housing for the wheel, a mating edge
for the bonnet and a strong box section for attachment to the side frames and front bulkhead.


• Front Wings
• - The front wings are each attached to the inner construction of the car body by
means of a flange along the length of the wing, which is turned inwards from the
outside surface and through which securing bolts can pass.
• - To add strength and to prevent vibration the wing brackets are sometimes fitted.
• - The unsupported edges are swaged and turned inwards to give strength& cracks
developing in the edges of the wings due to vibrations. This provides a smooth
finished appearance to the edges of the wings.
• - Apart from covering the suspension & wheel the wings prevent water and mud,
etc. being thrown up onto the body by the wheels.
• Door Panel Assembly
• - The door is composed of two main panels; outer and inner panel, constructed
to act as a frame for the door.
• - The outer panel flanges over the inner panel around the edges to form a single
unit.

• - The window channel may be welded or bolted to inner door panel to provide support & direction to
the window glass.
• - The inner panel has holes or apertures drilled, punched or formed for attachment of door trims.
• - The thickness of the door is due to the depth of the inner panel which accommodate door
catch,window mechanism,etc.
• - The inner panel forms the lock pillar and the hinge pillar sections of the door.

Sub- Assemblies &

Construction of Body Shell
• - Small reinforcement angles are
• usually used between the outer
• and inner panels where lock is
• inserted through the door and the
• hinges are attached.
• - The outer panel is provided with
• an opening through which
outside
• door handle protrudes.
Sub- Assemblies &

Construction of Body Shell
• Bonnet Assembly
• - The bonnet is the panel covering
• the engine compartment.
• - Most one-piece bonnets are
• hinged at the rear so that the front
• end swings up when opened. The
• catches are at front and in most
• cases controlled from inside the
car.


• Bonnet Panel Assembly
• - One-piece bonnets are quite large and, to make opening
easier, the hinges are usually counter - balanced by means of
tension or torsion springs.
• - Smaller bonnets are held in place by a stay
• - The bonnet consists of the outer panel and inner
reinforcement constructed in the ‘H’ or cruciform pattern. The
reinforcement is basically a top-hat section to give rigidity to
the component.
• - The main strength of the bonnet lies in the fact that the inner
construction acts like a frame and the outer panel is formed
round its edges, acting as flanges

• Boot Lid Assembly
• - The boot lid is composed of an inner and an outer
panel spot-welded together along their flanged edges to
form a single unit .
• - Both type of hinges ; external & concealed are used.
• - A catch is provided at the bottom rear of the boot lid
and controlled by an external handle. In some models
handles are not provided. The hinges are spring loaded
so that lid rises automatically by the hinge mechanism
for opening & holding it in place.
Body Build, Paint and Sealing

• Body build
• - A car body is made up of six major units ;
Floor, Two sides, Front end, Rear end, Roof
• - These major units themselves made up
from numerous smaller pressings reach
main body-build conveyors as sub-
assemblies
• - Special jigs carry the body floor assembly,
pairs of side frames, front & rear sections
mate up with the trucks so that all the units
are clamped securely together while the
welding is done. The roof is the last major
section to go on.

• Body build
• - Various forms of welding are used in building up a car
body shell like spot- welding, seam welding, etc.
• - After welding, every joint is sealed with special
compounds to make it a watertight car body.
• - After the body shells have assembled their doors,
bonnet panels, boot lids, etc. they are prepared for the
paint shop.
• - Panel surfaces are inspected and blemishes in the
sheet metal are removed with portable sanding
machines

• Painting
• - The painting of a car body means protection of
sheet metal, inside and out, underneath as well as on
top besides giving them a coat of bright shiny colour.
• - The first stage is a multi-part rust-proofing
treatment by complete immersion of the body shell
in a huge bath of anti-rust alkyd primer.
• - This is followed by surface priming. The entire
under body,wheel arches, insides of the body sills,etc.
are treated with multi-coats of epoxy primer followed
by baking in huge high- temperature ovens.


• Painting
• - The under body areas are coated with thick layers of bituminous or
polymer compounds for anti-corrosion protection. This also helps
reduce road noise.
• - In final stage the complete body is given a base coat of acrylic paint
with special adhesion qualities. This is followed by multi-coats of the
finish colour paint which is basked in hot oven to create a hard, deep-
gloss finish.
• - In between these operations rubbing, washing, cleaning, etc are
carried out .


• Sealing
• - The entire car body is vulnerable to the entry of water,
fumes, and dust.
• - The various locations on the vehicle body that require
some form of seal are ;
• 1. Areas where a permanently flexible seal is required,
e.g. windscreen, rear screen
• 2. External panel seams.
• 3. Areas where a seal is required to withstand stone
pecking, e.g. wheel arches, floor pan
• 4. Protected areas where a bulk sealer is required

• Sealing
• - It is essential for the various sealing materials ( caulking cmpound, multi-
purpose adhesive, metal joint sealer, windshield sealer, double-sided
adhesive tape, PVC foil, etc. ) to be applied to clean dry surface if they are
to adhere and form an effective seal.
• Fixtures and fittings
• - From paint shop the car body pass into the trim shop for ‘furnishing’
where various items like carpets, seats, door handles, window glass,
chrome moldings, electric wiring, steering wheel,fascia panels,instrument


• Fixtures and fittings clusters, etc. are fitted
• - Midway through this long furnishing the body pass through a
long water tunnel where it is drenched by powerful jets of water.
This water contains a fluorescent dye and any drop of water that
may have found its way into the body can be detected.
• - Before the bodies leave the trim-shop some minor mechanical
units are added and transferred to the ‘body drop’.

Unit IV
Body Terminology, Visibility & Space

Unit IV Body Engineering Terminology
Body Engineering Terminology

Tailfin
• The tailfin era of

automobile styling
encompassed the 1950s
and 1960s, peaking
between 1957 and 1960. It
was a style that spread
worldwide, as car
designers picked up styling
trends from the US
automobile industry where
it was the golden epoch of
American auto design

Unit IV Center console
The center console in an

automobile refers to the control-
bearing surfaces in the center of
the front of the vehicle interior.
The term is applied to the area
beginning in the dashboard and
continuing beneath it, and often
merging with the transmission
tunnel which runs between the
front driver's and passenger's
seats of many vehicles
Fascia
Fascia often refers to the decorative panels of a car's dashboard or the entire
dashboard assembly

Fender skirts
Fender skirts,
known in Australia
and the United
Kingdom as spats,
are pieces of
bodywork on the
fender that cover
the upper portions
of the rear tires of
an automobile

Glove compartment
A glove compartment
or glovebox or glovie is
a compartment built
into the dashboard,
located over the front-
seat passenger's
footwell in an
automobile often used
for miscellaneous
storage

Greenhouse
The greenhouse (or
glasshouse) of a car
comprises the windshield
rear and side windows,
the pillars separating them
(designated A-pillar, B-
pillar and so on, starting
from the car's front), and
the car's roof

Hood scoop
A bonnet/hood scoop, sometimes called bonnet airdam /air dam, or
colloquially speed hole, is an upraised component on the hood of an
automobile that either allows a flow of air to directly enter the engine
compartment, or appears to do so

Nerf bar
A nerf bar is a tubular device fitted to the side of a racecar, typically single-seat
race cars that compete on asphalt or dirt oval tracks. A "nerf" is a small,
sometimes intentional, collision between two cars in which one driver bumps
the other to facilitate a successful pass. The nerf bar protects the sides of the
vehicles and also keeps their tires from becoming entangled

Power bulge
A power bulge is a raised part (a bulge) of the hood of a car. The reason for a
power bulge is to fit for instance a large engine or air filters that otherwise
would not fit. Sometimes a power bulge is used to be able to fit a larger engine
into a car that originally was not designed for it or it may be a design choice to
be able to get a lower profile. As a power bulge is associated with performance
cars it may also be used as a design element to give the impression of a fast car

Quarter panel
A quarter panel is the body panel
(exterior surface) of an automobile
between a rear door (or only door
on each side for two-door models
and the trunk (boot) and typically
wraps around the wheel well. The
similar front section between the
door and the hood (bonnet) , is
called a fender but is sometimes
incorrectly also referred to as a
quarter panel. Quarter panels are
typically made of sheet metal, but
are sometimes made of fiberglass
or fiber-reinforced plastic



Body Body Sill : The panel (metal plate) directly

Engineering
below the bottom of doors supporting the floor
Terminology
and may be used to combine floor & body.

- Bonnet : The metal cover over the engine

compartment
- Bulk Head : A transverse support or assembly in a

body structure.
- Boot : A compartment which takes luggage and

often the spare wheel & fuel tank
- Center Pillar : The central vertical support of a four

door saloon, sometimes referred to as B-C post

Body - Cant Rail : The longitudinal framing of the roof at

Engineering the joint
Terminology
- Cant Panel : The curved section of the roof top

running between the comparatively flat top and
the rain channel
- Door Skins : Door exterior panels/outside door
panels
- Door Trim : The interior lining of a door

- Drip Moulding : A roof gutter to direct water from door

openings
- Fire wall : Panel dividing engine compartment from
passenger compartment

• Head Lining : The material, cloth, PVS, etc.

• Heel Board : A vertical board or panel rear seat
which forms the support for the seat cushion
• Hinge Pillar : A pillar on which the door swing
open or close
• Pillar : A vertical support of a body frame
• Quarter Panel : The curved side panels extending
from the door to the rear end of the body
including the wing or the curved panels which
connect the side panels, including the rear wing


• - Quarter light : The window directly

above quarter panel
• - Scuttle Panel: The panel between
bonnet & windscreen
• Sub- frame : Members to which the
engine & front-end assembly are
attached
• - Tunnel : A raised floor panel section
for drive shaft clearance
• - Wheel arch : A break in the rear
panels to accommodate the rear
mudguards and wheels
• - BBC : Abbreviation for the distance
from the bumper to the back of cab


• - Sub- frame : Members to which the
engine & front-end assembly are
attached
• - Tunnel : A raised floor panel section for
drive shaft clearance
• - Wheel arch : A break in the rear panels
to accommodate the rear mudguards
and wheels
• - BBC : Abbreviation for the distance
from the bumper to the back of cab

• - Bearers : The cross- members that support the

body floor. They are located on either chassis
member or longitudes
• - Bulker : A general term for vehicles carrying
liquid and powder
• - Cab : The part of a vehicle enclosing the driver
• - Cant rail : The member which connects the side
panels of vans to the roof structure

• - Cleat : Bracket used for joining longitudinal transverse

body members
• - COE : Abbreviation for “cab over engine”
• - CV : Abbreviation for “commercial vehicle”
• - Drop side panels : Hinged panels which are fitted to
the sides of platform bodies
• - GRP : Abbreviation of glass reinforced plastic used for
vehicle roofs and vehicle cab
• - GVW : Gross Vehicle Weight is total weight of vehicle
• - Longitudes : The main longitudinal members of a body
which normally rest upon the chassis

• Overhang : The dimension from the center-line of the

rear axle to the rear of the body
• Pay load : The difference between gross vehicle
weight and unladen weight , that is carrying weight of
vehicle
• Rave : Often referred to as bottom rail, this is the
longitudinal section which mates with the outer
extremities of the floor & bearers and in case of vans,
connects with the side panel
• Rub rail : A longitudinal section fitted to van sides in
order to minimize damage to side sheets

Requirements of Automobile Body
• A frameless type body of an Automobile must

satisfy requirements in terms of :
• Strength
• Stiffness
• Space
• Air Drag
• Protection against weather
• Resistance to Corrosion
• Protection in accident

Strength : Body must withstand all types of forces to which vehicle is

subjected to ;
• - weight of the vehicle, passenger, luggage

• - inertia, braking, & side forces
• - impact loads of reasonable magnitude
Stiffness : Body may be considered as a beam supported on wheels at

each end. It must possess sufficient stiffness to prevent sagging in the
middle.
Torsional Stiffness : Body should be sufficiently rigid to resist twisting on

bad roads.
Space : Adequate space to be provided in the body for passenger and

luggage.

Air drag : Resistance of air during vehicle movement depends upon body
shape. The shape of the body should be such that the air drag is
minimum
Protection against weather : Body should be such that the occupants and
luggage not affected from weather.
Resistance to Corrosion : Body should be designed such that no moisture

is accumulated and material should be such that rust & corrosion does
not take place.
Protection in accident : It is an important consideration of vehicle body

design. Driver must be at maximum ease to avoid accident due to fatigue.
However, body should be designed such that the occupants are best
protected even in case of accident

Visibility
• Good all round visibility

is one of the main
requirements of body
design
• Visibility depends upon
the window opening and
their relative position to
the occupants
• Figures below show eye
position of driver, angle
of visibility & space
between the pillar and
seat
1x2z
Improvement in Frontal visibility

Visibility
• Types of Visibility
• - If occupant is placed close to windscreen the
forward visibility is considerably improved but
comfortable entry is adversely affected as dimension
between pillar & seat is decreased requiring suitable
shaping of the door, if possible.
•- Downward visibility can be improved by
positioning the driver as high as possible in relation
to the lower edge of windscreen.
• - Rearward visibility is achieved by increase in glass
area required to maintain rear view vertical angle
with back window

Space Requirements & Methods of its Improvements
• Amount of space has to be allocated to passenger needs according

to dimension & type of body
• Space for access to fuel tank, spare wheel, batteries, tools, boot, and
spare wheel placing, etc. depend upon dimension & type of body
and the inventiveness of the designer.
• Window opening should ensure good visibility without affecting
stiffness of the body shell.
• Main requirement of door opening is the comfort of entry
• In two door design passage way to back seat should be ensured

Measurement of comfortable passage way is shown in figure.

• Avoid pockets for the feet by sloping the door post & side walls as
shown.

• Considerable experience in design is needed to position the

compartments in a planned outline of the body.
• Good utilization of space is particularly significant for small vehicles
and in general makes the vehicle lighter resulting in improved
power-to-weight ratio. This reduces cost of vehicle also.

Unit IV
Design Considerations & Body Construction

Unit IV Design Considerations &
Body Construction
Morphology of Vehicle Body ( Structural ) Design
• Emancipation of the Body Designer

•- A wide range of skills required for vehicle design and
manufacture
•- Development of motor vehicle may require following
group of activities;
• Technical innovation and refinement
• Construction and configuration by Designing & Styling
• Methods of production, and manufacturing systems

Body Construction
• Technical innovation and refinement

•- Innovative developments have often been the work of
several different engineers working in parallel but
independently
• - Many apparently new inventions are adaptations from
different technologies, e.g.,
• differential mechanism used by watchmakers, aerospace,
electronics, materials,etc.

Body Construction

• Methods of production and manufacturing systems in early
times were adaptations from horse-drawn carriage
construction methods for upper body works.

Body Construction

• Above a wooden chassis, sat a light wooden framework
covered with a skin of sheet metal, wood or fabric.
• As motor vehicles had to sustain loads and vibrations of
engine, transmission and of vehicle dynamics at higher speeds
( higher shock loads ) the metal chassis frame were quickly
adopted

Body Construction

• A combination of steel chassis, wooden framework
and sheet metal skinning were used for most vehicle
with aluminum often used in more expensive and
higher performance vehicles

Body Construction

• A few fabric and wooden bodied vehicles were still produced
as late as 1930s by specialist coach builders mainly because
the antiquated style conveyed an air of past elegance.
• Subsequently increasing use of pressed – steel skin panels in
place of flat sheets or hand beaten or wheeled panels
followed.

Body Construction

• Sheets of steel were pressed in moulds to produce complex
shapes with multiple curvature and the process enabling
economic production bulbous styling forms, that became
popular, took over

Morphology of Vehicle Body Construction
Body ( Structural ) Design

• Multiple curvature also made panels much stiffer and the
skin could take a significant part of load.
• Some manufacturers began to dispense with wooden
frames and use metal frame or even no frame work at all,
relying on panels & formed sheet metal stiffening elements
to provide all rigidity necessary for upper body

Body Construction

• Lower chassis frames initially retained but separate chassis
began to disappear, being replaced by a stiff floor ‘pan’ that
was fabricated from welded shaped sheet elements.
• By 1950s ‘unitary’ type of construction was almost universally
adopted for mass-produced cars.
• Recently, the shell construction has been refined to produce
smooth aerodynamically shape with minimum protrusions or
gaps.

Body Construction

• Composite construction in fiberglass and resin was developed
soon after the war

Body Construction
Mass Production - Designing & Styling
• Two giants of vehicle manufacture following

World War I were Ford and General Motors
• Initially Ford were predominant with
standardized Model-T car & van

Body Construction
• Ford fathered mass production and design

standardization.
• GM in addition recognized another strong force
in the market place: customers personal
preference
Mass • - sectorized market & designed accordingly
Production - • - offer proliferation of body shapes & colours
Designing & • - in mid 20s GM gave birth to ‘ Stylist’
Styling • GM was outselling Ford. Serious business of
body design took its place amongst industry
professionals.
• A stylist would ‘package’ occupants and
luggage around a fairly standardized layout of
engine and drive train.

Body Construction
Design Considerations
• Task Assignment
• General layout
• Artistic utilitarian design
• Dummies & models
• Preliminary design
• Body weight, stress, geometric analysis, etc.
• Master model and mathematical models
• Scanning of master model with electronic sensors and
compilation of data
• Scanned data integration and analysis with the help of

Body Construction
• computers to generate geometrically perfect

surfaces & reproduction of tapes
• Tapes are used by numerically controlled machines
(e.g. milling ) to prepare high precision dies
• These dies are used by Power Presses to produce
the Pressed Metal Panels which are welded
together to construct the structures and body of
the vehicle

Body Construction
• Task assignment :
• - The task of designing of vehicle is broken down into various
components ;
• Body / Chassis / Engine / Transmission
• - Consider components need to be designed and the
components to be used as standard items, e.g, transmission
system.
• - Consider ergonomics of seating &controls, legal requirements
of body, engine, etc. field of vision, aerodynamics, etc.

Body Construction
• General layout :
• - Designer in consultation with Stylist prepares
perspective drawings & sketches
• - Construct suitable models or mock-ups and initial
design drawings
• - Carryout structural analysis on body design and
compare new design with existing designs to ensure
• some advances made
• - Finalize basic dimensions, often called ‘ package of
the vehicle ‘ and include overall dimensions as per
legal requirements

Body Construction
Design General layout :

Considerations
- As per above the external dimensions, wheel-base, etc.

are decided and a general layout is prepared as shown :

Body Construction
• Artistic Utilitarian Design :

• - Aesthetically pleasing body shape is set out
considering aerodynamics and other design
requirements
• - The design of a shape based on the elements of
functions and logic together with an artistic
appreciation of forms is called “ artistic utilitarian
design “. Such designs have advantage over irrational
styling and is a necessary part of good design.

Body Construction
• Dummies & Models :

• - The dimensionally complicated form of
vehicle bodies require practical checking at
all stages of design. These are carried out
by means of dummies and models
Design
Considerations • Dummies :
• - Dummies are built to ensure that the
principal dimensions are compatible. This
includes dimensions of driver’s position,
passenger’s seat, size of door & window
openings, etc.

Body Construction

• - A full scale dummy allows for complete
reproduction of the drawing dimensions
and thus check for comfort, visibility, ease
of exit & entry, position of steering wheels,
chassis - engine mechanisms, layout of
Design dashboard, etc.
Considerations • - Dummies are usually constructed in timber
and / or other synthetic materials which are
easy for manual working.
• - Apart from checking dimensions of the
body the position of components can be
determined using

Body Construction

• chassis & engine either real or their dummies
• Models :
• - Inside dimensions of a vehicle body, having being
checked & finalized with dummies, form the basis for
developing models of the outside surfaces of the
body.
• - Scale models ( say 1 in 20 ) are constructed using
materials like plasticine or plaster of paris laid on a
wooden base with tools such as knives & spatulas,
etc. Some scribing devices are used as measuring

Body Construction
• Models :
• the principal sections ( called outlines ) are transferred
onto the model using templates.
• - A few variants of a model with corrected basic sections
of the design are considered for finally choosing the
model for obtaining templates for larger scale models (
say 1 in 5 ) such that it represents vehicle in details as far
as possible. Such a model is called a “ reduced model “
• - the principal dimensions of the vehicle are determined
by the development of such models and

Body Construction
• Models :
• and dummies, and the first outlines of the
drawings can be made without details.

Body Construction
Material Requirements and Body Parts
• Steel Sheets used for making Car Bodies :

• - Low tensile strength and high ductility for ease of forming
• - Easily assembled to form a body unit
• - Light in weight
• - Low cost
• A Typical Low-Carbon Steel Composition
• Carbon - 0.080 % Phosphorus - 0.020
%
• Silicon - 0.002 % Manganese - 0.350 %
• Sulfur - 0.020 %

Body Construction
• The liquid steel is cast into large ingots for subsequent

hot - rolling to sheets of different thickness. Typical
sheet thickness & their use are :
• 10g 3.25mmbrackets & supports and heavy
• 12g 2.65mm internal construction
• 14g 2.03mmpanel assemblies which take
• 16g 1.63mm stresses & loads ( floor bulk head,
• 18g 1.22mm sills, sub-frames, cross-members
• and inner stress panels )

Body Construction
• 20g 0.95mmouter panel construction ( skin

• 22g 0.71mm panels, doors, bonnet, boot,
lid,wing panels )

Body Construction
• Comparison between Steel & Aluminum

• - The requirements of Fuel Economy &
Environment has demanded Vehicle Body weight
reductions.
• - Aluminum has been considered strong alter
native to steel in order to achieve weight reduction.
However, the magnitude of weight reduction has to
be attractive despite its higher cost.
• - Generally, Aluminum has been found better in
castings for housing, engine blocks, etc resulted in
savings in weight & costs

Body Construction

• - The compelling demand for change in material
• properties has been the need for reduced weight
• - To meet such demand a new generation
improved
• high-strength steels has been developed that offer :
• I) sufficient ductility to meet fabrication
requirements
• ii) meets the minimum yield strength requirements
• iii) improved conductivity & weldability

Body Construction

• - Comparison of Relative Material
Material Properties of Aluminum ( Base Steel = 1
Requirements )
and Body • I) Tensile Strength 1/3
Parts • ii) ductility 1/2
• iii) density 1/3
• iv) elastic modulus 3

Body Construction

• - Considerations for Competitiveness
• For tensile strength limited applications
replacement of steel by aluminum requires a
cross-section that is
• three times greater which makes it approximately
equal in weight for equivalent modulus of
elasticity. Overall it means three times the cost.

Body Construction

• Factors for material selection for Car Body Pressings
• - Yield strength
• - failure strength
• - formability
• - indentation resistance
• - fabricability
• - painting systems / requirements
• - Welding
• - Heat - Treatment

Body Construction

• Some Comments / Observations
• - Most automotive components are not loaded in pure
tension, but where simple tensile properties are the
design criteria, a steel with higher yield strength is
capable of saving about 40% of weight and may be
comparable .
• - Functional requirements vary from simple bending
or indentation resistance to complex twisting and
structural loading of components. By changing to
higher-strength steel, appreciable weight reductions
Body Construction

• can be obtained. The type of improvements
generally achieved by increasing the product
strength can be as high as 30%.
• - Welding : Aluminum parts require increased
thickness ( 1.4 times ) and larger dia. Electrodes
for welding & greater edge distances for
equivalent weld-bond strength. Disparity
increases as thickness increases. At about 2.2mm
steel
AABE by R P provides
Kakde 3 times strength advantage.
GCOEARA Awasari Khurd
Body Construction

• Welding :
• - In order to improve inherent lack of spot
weldability of aluminum sheets the adhesive
bonding & welding may be used to achieve
satisfactory strength. This may have additional
cost implications.
• - Oxide coating of aluminum vary significantly
and cause production of unacceptable
AABE by R P Kakde
welds.
GCOEARA Awasari Khurd
Body Construction

• In summary, steel has many inherent
advantages over aluminum for
applications in pressings however, aluminum
has advantage in castings for housings,
engine blocks, etc.

Unit IV
Vehicle Body Engineering
Body & Safety Considerations

Unit IV Body & Safety Considerations
Introduction
• Designer should ensure maximum safety of the

driver, passenger, and other road users
• Vehicle should be designed to reduce the
effects of collision and ensure minimum injury
• Stylists should avoid sharp ornaments, edges
and projected elements. Careful attention to
door handles, mirrors, hooks, control
knobs,etc. reduces injury to pedestrians and
also affects in reduction of aerodynamic drag
& noise.
Safety Features Of Vehicles can be grouped as :
• Vehicle Body Structure, its Systems & Parts

• Additional Safety Features & Systems
• General & other safety recommendations

Safety Features Of Vehicles :
• Vehicle Body Structure, its Systems & Parts

• Basis of body design for safety
• Safety features of Door system
• Window Glasses & Windscreen
• Bumpers
• Seat back & head restraints
• Rear view mirrors
• Ventilation

Vehicle Body Structure, its Systems & Parts
• Basis of body design for safety

• - The design of vehicle body for optimum
characteristics should be based on basic energy
relationship
• - The kinetic energy of a vehicle destroyed during a
collision is absorbed by the workdone on materials
by elastic deformation

Basis of body design for safety
• The kinetic energy of a vehicle destroyed

during
• a collision can be expressed as
• K.E = ( m - m ) V2 / 2
• where ;
• m = total mass of vehicle
• m = moveable mass(passenger or load)
• V = Velocity

Workdone on materials by elastic deformation is

 Pds = (2 / 2E) A L
where; P = force generated during collusion on
vehicle structure
S = distance traveled during the collision
E = Young’s modulus, Stress/Strain
A = cross sectional area of the structure
 = local stress in the material
L = deformation in cm

• Safety Features of Door System

• - Photo - electric beam door closes automatically at pre -
determined time
• - Gear shift lock prevent selection of gear until all exit
doors are closed
• - Electrically sensitive edge on exist door causes
automatic opening if obstruction is encountered
• - Pneumatic - sensitive - edges give audible and visual
warning to the driver of door obstruction

• Safety Features of Door System

• - Transmission interlock prevent opening of doors whilst
vehicle is in motion
• Window Glasses
• - Shatter proof glass should be used. When hit against
any object the whole glass falls out and there will be no
sharp edged pieces

• Window Glasses
• - In bullet proof glass when hit there will be no normal
angle of incident (inclination). The bullet is thrown out
as there will always be some angle of incident.
• Reliability / Safety Requirements Windscreen
• - Freedom from faults which interfere with vision


• - High transparency & freedom from visual distortion
• - External durability to reduce surface degradation &
scoring from wipers, ice scrapers, road grit, etc.
• - Vision not affected by normal road stone impacts


• - Retention of impacting occupant with low
• deceleration to avoid brain damage
• - Fragment formation should not expose the
• face & head to risk of severe laceration.
• Bumper
• - Shock absorbers behind the bumpers may be used. In
some designs semi - circular

• Bumper shape is adapted. This avoids direct collision

and tilt of the vehicle.
• - Bumper design & height should be such that in case of
accident it hits passenger below the knee. In this case
the passenger will fall on to the vehicle otherwise on
road which would be more dangerous.

• Seat - Back & Head Restraints

• - Seat-backs should be in an upright position to get
maximum protection from the seat belts
• - In reclined seat-back position the risk of sliding under
the seat belt increases in a severe crash.
• - The front head restraints help from whiplash and other
injures.

• Seat - Back & Head Restraints

• - For most effectiveness, the Head Restraint should be
adjusted such that the top of the restraint is even with
the top of the ears as shown

• Ventilation
• - Proper air vents directed towards the windscreen, side
windows,passenger compartment, front and rear
passenger foot walls should be provided.
• Rear View Mirror
• - Inside rear view mirror can be adjusted up, down or
sideways to obtain the best view. Always adjust the
mirror set to day positions

• Rear View Mirror

• - Outside rear view mirror can be folded flat against
the side of the vehicle and can be inclined at an angle
to position it properly. The size or distance of a vehicle
or object seen in an outside convex mirror look smaller
and appear farther away as compared to a flat mirror.

Safety Features Of Vehicles can be grouped as :
• Additional Safety Features & Systems

• ABS braking system
• Seat belts
• Air bags
• Flashers & horns
• Child safety

Additional Safety Features & Systems

• - The ABS braking system prevents the wheels from
locking when braking
• - It makes the best road grip and provides safest
control during emergency braking under difficult road
conditions.
• - The driver can feel as ABS comes into play when the
brake pedal pulsates slightly and the system gets
noisier.


• - This indicates that the ABS is working and vehicle is
travelling at the limit of the road grip, and the vehicle
speed should be changed to fit the type of road surface.
• - The ABS is in addition, if failure occurs the basic
braking system continue to work.
• - The advantage of the system is to give maximum
maneuverability by preventing the


• the wheels from locking.
• - The light on the dash board warns driver to reduce
speed.

• Seat Belts
• - Need & Requirements : Inside a moving car, if car suddenly stops,
the occupant get hurled forward as the car has decelerated or
stopped due to impact but occupant keep moving at about same
speed as the car at the time of impact. So the body, particularly the
head & chest smash into whatever is in front;windscreen,dash
board, steering wheel


• Seat Belts
• Sometimes the occupant can be thrown out of the
car through windscreen or opened door. It is not
only the front seat passengers who are at risk but
also the back seat passengers.
• Seat Belts restrain occupant & holds back to the
• seat - preventing from hitting any hard structure in
the car

• Seat Belts
• - Construction : Seat belt comprise of a lap band
and shoulder band held in place by single
buckle, and bolts fastened to the car body.
• - Types : Seat belts are of two types ; non-
retracting and automatic-retraction. First type
do not adjust to wearer’s movement & not
convenient. The second type allows to

• Seat Belts
• move around freely. It has mechanism that
restrains the occupant when car hits or stops
suddenly.
• - Precautions to be observed : Seat belts are
designed to bear upon the bony structure of the
body, and should be worn low across the front of
the pelvis, chest, and shoulders. Seat belts
should be adjusted as firmly as

• Seat Belts
• possible. Belt should not be worn with straps
twisted. It is dangerous to put belt around a
child being carried on the occupant’s lap.
• Working of the Seat Belt System :
•- Lap/Shoulder Belt has a single belt that
goes over the shoulder, across chest, and across
pelvis as shown in figure.

• - In normal driving, the belt fitted

with a locking retractor allows
occupant move freely in the seat
while keeps tension on the belt.
During a collision or sudden stop the
retractor automatically locks the belt
to help

restrain body.
- Before putting on the seat belt move seat as far back as possible,seat
back to be up upright and there should be no twists in the belt.
Air Bag
-Air bag is a safety device that protects the driver & the front seat
passenger during head-on collision
- Air bag is an instantly inflatable cushion stored in the center pad of

steering wheel and in the dash board on passenger side

• - In case of a collision of magnitude exceeding the

set value, the sensor activates the mechanism and
cushion inflates instantly to act as a soft protecting
• barrier

• Hertomatic Flashers and Horn (beep noise)

• operate for every one minute, if not attended
then ultimately the ignition will be automatically
switched off.
• Child Safety
• - Infants and young children should always be
properly restrained whenever they ride in a car
as shown

• Children should ride in rear seat and not in lap of

• adults. Place the child restraint in the seat with a
• lap/ shoulder belt through the restraint ( infants
• & toddler seat ). Use child proof door locks

General & other safety recommendations
• There should be no loose items inside vehicle which

could be thrown around and may hurt during accident
or sudden braking / stops
• Luggage should be securely stored or tied downed
• Seats should be upright, head restrain adjusted, & seat
belts fastened
• Vehicle operation control should not be obstructed
• First-Aid kits should be available

General & other safety recommendations
• Driver should not be under the influence of alcohol or

drugs
• Ensure all doors are properly closed
• Ensure buckling up of children and child constraint system
is properly installed

Unit 4a Vehicle Body Engg Cars

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Automotive Aerodynamics & Body Engineering

Vehicle Body Engineering

AABE by R P Kakde GCOEARA Awasari Khurd

After studying this chapter, we should be able to:

Compare and contrast modern

AABE by R P Kakde GCOEARA Avasari Khurd

Identification & Functions of Body Pressings

• In a separate body and chassis construction :

AABE by R P Kakde GCOEARA Avasari Khurd

AABE by R P Kakde GCOEARA Avasari Khurd

Identification & Functions of Body Pressings

AABE by R P Kakde GCOEARA Avasari Khurd

Identification & Functions of Body Pressings

• Box sectioning of the body sills, door pillars and roof

AABE by R P Kakde GCOEARA Avasari Khurd

Identification & Functions of Body Pressings

• Mass production of car bodies in steel consists of manufacturing of sub-

AABE by R P Kakde GCOEARA Avasari Khurd

Sub- Assemblies & Construction of Body Shell

AABE by R P Kakde GCOEARA Avasari Khurd

AABE by R P Kakde GCOEARA Avasari Khurd

Sub- Assemblies & Construction of Body Shell

AABE by R P Kakde GCOEARA Avasari Khurd

Sub- Assemblies & Construction of Body Shell

• Under body assembly

AABE by R P Kakde GCOEARA Avasari Khurd

• Body side assembly

AABE by R P Kakde GCOEARA Avasari Khurd

AABE by R P Kakde GCOEARA Avasari Khurd

Sub- Assemblies & Construction of Body Shell

AABE by R P Kakde GCOEARA Avasari Khurd

Sub- Assemblies & Construction of Body Shell

AABE by R P Kakde GCOEARA Avasari Khurd

AABE by R P Kakde GCOEARA Avasari Khurd

Sub- Assemblies & Construction of Body Shell

AABE by R P Kakde GCOEARA Avasari Khurd

Sub- Assemblies & Construction of Body Shell

AABE by R P Kakde GCOEARA Avasari Khurd

Sub- Assemblies & Construction of Body Shell

AABE by R P Kakde GCOEARA Avasari Khurd

Sub- Assemblies & Construction of Body Shell

AABE by R P Kakde GCOEARA Avasari Khurd

AABE by R P Kakde GCOEARA Avasari Khurd

Sub- Assemblies & Construction of Body Shell

Sub- Assemblies & Construction of Body Shell

AABE by R P Kakde GCOEARA Avasari Khurd

Sub- Assemblies &

Sub- Assemblies &

AABE by R P Kakde GCOEARA Avasari Khurd

Sub- Assemblies & Construction of Body Shell

Sub- Assemblies & Construction of Body Shell

Body Build, Paint and Sealing

Body Build, Paint and Sealing

Body Build, Paint and Sealing

AABE by R P Kakde GCOEARA Avasari Khurd

Body Build, Paint and Sealing

AABE by R P Kakde GCOEARA Avasari Khurd

Body Build, Paint and Sealing

Body Build, Paint and Sealing

AABE by R P Kakde GCOEARA Avasari Khurd

Body Build, Paint and Sealing

AABE by R P Kakde GCOEARA Avasari Khurd

AABE by R P Kakde GCOEARA Awasari Khurd